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American National
Standard (ANSI)
ANSI/EASA
A R 1 0 0 - 2 0 10
RECOMMENDED
PRACTICE
FOR THE REPAIR OF ROTATING
ELECTRICAL APPARATUS
ICAL APPA
TR R
AT
C
ELE
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EA SA
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Reliable Solutions
Today
EASA AR100-2010 Recommended Practice - Rev. October 2010
EASA AR100-2010
Recommended
P ra c t i c e
for the Repair of Rotating
Electrical Apparatus
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EASA AR100-2010 Recommended Practice - Rev. October 2010
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Table of Contents, Page 1
TABLE OF CONTENTS
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Table of Contents, Page 2 EASA AR100-2010 Recommended Practice - Rev. October 2010
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 1, Page 1
Section 1
General
1.1 PURPOSE 1.4 CONDITION ASSESSMENT AND
The purpose of this document is to establish recom- FAILURE INVESTIGATION
mended practices in each step of rotating electrical The service center should inspect and test the ap-
apparatus rewinding and rebuilding. paratus to confirm its condition and obtain data for
1.2 SCOPE any failure investigation. For the latter, data collec-
tion should proceed before any work is carried out.
This document describes record keeping, tests,
Inspect all parts for defects before and after cleaning.
analysis, and general guidelines for the repair of
Document any evidence of distress, such as physical
rotating electrical apparatus. It is not intended
damage, overheating, tampering, oil levels, electrical
to take the place of the customer’s or the machine
tracking, or encounters with animals. If possible,
manufacturer’s specific instructions or specifications.
obtain information about operating conditions at
Excluded from the scope of this document are
specific requirements, certification, and inspection the time of failure. Collect and carefully examine
required for listed explosion proof, dust-ignition- any debris from any fault.
proof, and other listed machines for hazardous 1.5 INSPECTION AND CLEANING
locations; and specific or additional requirements 1.5.1 Inspection
for hermetic motors, hydrogen-cooled machines,
Inspect all parts for wear and damage before and
submersible motors, traction motors, or Class 1E
after cleaning.
nuclear service motors.
Insulation should be examined for evidence of
1.3 IDENTIFICATION degradation or damage, such as:
1.3.1 Service Center Labeling (1) Puffiness, cracking, separation or discolor-
Machines received for repair should have the re- ation as indication of thermal aging.
pair company’s name or identifying logo and shop (2) Contamination of coil and connection surfaces.
order number permanently embossed or inscribed (3) Abrasion or other mechanical stresses.
adjacent to the nameplate on the frame for future (4) Evidence of partial discharges (corona).
reference. This shop order number should be listed (5) Loose wedges, fillers, ties, banding, or surge
on the repair invoice. rings.
(6) Fretting at supports, bracing or crossings (an
1.3.2 Records indication of looseness or movement).
A record of each machine received for repair should (Reference: IEEE Stds. 432, Sec. 5.)
be established at the time of receipt and kept on file Bars and end rings for amortisseur and squirrel
for at least 3 years. The record should include the cage windings should be examined for evidence of
nameplate data, electrical test data (both before and defects. Testing may be needed (see Paragraph 4.3.2).
after repair), mechanical measurements (both before
and after repair), original winding data, final wind- 1.5.2 Cleaning
ing data, and details of replaced parts. This record All windings and parts should be cleaned. Dirt,
should be made available to the customer for review grit, grease, oil, and cleaning agents should be re-
if requested. The primary cause of failure should be moved. Windings and parts should then be dried.
determined, if possible, and should be recorded on 1.6 TERMINAL LEADS
the apparatus repair record. All apparatus should be equipped with lead wire
1.3.3 Nameplate of rated temperature and voltage insulation and of
An electrical machine should have a permanent sufficient current carrying capacity. The tempera-
nameplate containing the principal information ture rating should be appropriate for the duty and
needed to put the machine into service. The original any oven curing process, and allow for the effect of
nameplate is preferred. If a machine is redesigned, heat transfer to the terminals.
the original nameplate should remain on the unit All leads should be suitably marked or colored
and a new nameplate mounted adjacent to it with where necessary to indicate correct connection. Lead
the word “redesigned” and the new rating and date markings should conform to original manufacturer
of redesign shown. The original nameplate may be markings, NEMA Stds. MG 1 or IEC Stds. 60034-8,
reversed (blank side out) to prevent misinterpreta- whichever is applicable.
tion, but it should remain with the frame. Leads and markings should be of sufficient du-
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Section 1, Page 2 EASA AR100-2010 Recommended Practice - Rev. October 2010
rability to withstand the environment involved boxes. Gaskets and seals should be replaced where
and be of sufficient length for ease of connecting necessary.
to power supply at the terminal box or to terminal 1.9 COOLING SYSTEM
blocks. Leads on totally enclosed apparatus should The fans and cooling ducts should be clean and
be properly sealed to meet environmental operating operational. Cover plates and air baffles should be
conditions. in place. Damaged or missing parts of the cooling
A print or plate should be furnished, where neces- system should be repaired or replaced.
sary, indicating correct connections.
1.10 EXTERIOR FINISH
1.7 TERMINAL CONNECTORS
Apparatus should be externally cleaned and
The recommended method of attaching terminal painted. Shaft extensions should be treated to pre-
connectors (lugs) to lead wire is by crimping or vent corrosion.
pressure indenting the lug barrel, using a lug sized
to suit the particular cable stranding provided, in 1.11 PACKAGING AND
TRANSPORTATION
accordance with recommendations of the lug manu-
facturer. After completion of the repair and testing, the ma-
Damaged or missing lugs should be repaired or chine should be packed in a manner suitable for the
replaced. form of transport to be used. Packing and transport
should be as arranged with the customer. Blocking
1.8 TERMINAL BOXES of the shaft is recommended, depending on the type
Terminal boxes should accommodate the connec- of machine, mode of transport and the distance to
tions without crowding. Missing terminal boxes be traveled. Where blocking is used, it should be
should be replaced, and damaged terminal boxes clearly identified. Oil-lubricated machines should
should be repaired or replaced. See NEMA Stds. be shipped without oil, and the need for lubricant
MG 1, 4.19 for guidance on replacement terminal clearly identified.
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 2, Page 1
Section 2
Mechanical Repair
2.1 SHAFTS 2.2.2.3 Seals
Shafts should be checked for wear, cracks, scoring Seal clearance should be set to original equipment
and straightness. Shaft extension dimensions should manufacturer’s specifications if available. Other-
be checked. wise, the values in Table 2-7 are provided as a guide.
2.1.1 Diameter Tolerances Measure the final seal dimensions.
• NEMA frame size machines: See Table 2-1. 2.3 LUBRICATION
• IEC frame size machines: See Table 2-2. 2.3.1 Grease
2.1.2 Permissible Runout Grease passages and pipes should be clean. Grease
• NEMA frame size machines: See Table 2-3. inlets should be equipped with fittings. Lubricant
• IEC frame size machines: See Table 2-4. should be compatible with the customer’s lubricant.
2.1.3 Keyseat (Keyway) Width Open bearings should be filled with grease during
Tolerances assembly.
In the absence of the machine manufacturer’s
• NEMA frame size machines: See Table 2-5.
lubrication instructions, the grease reservoir should
• IEC frame size machines: See Table 2-6.
be filled to approximately 1/3 capacity.
Keyseats should be true and accommodate keys
to a tap fit. 2.3.2 Oil
Lubricant, including oil for test operation, should
2.2 BEARINGS
be compatible with the customer’s lubricant . There
Bearings should be inspected for fretting, fluting, should be a means to indicate proper oil level, such
frosting, scoring or other damage. as an oil sight gauge. Evidence of oil leaks should
2.2.1 Ball or Roller Bearings be investigated and the cause corrected.
Bearing housing and shaft bearing fits should be 2.4 FRAME AND BEARING HOUSINGS
measured and compared to design specifications
(Reference: ANSI/ABMA Stds. 7 as a guide). Any 2.4.1 General
fits that are not within tolerance should be restored. Frame and bearing housings should be examined
See Tables 2-13 and 2-14. Replacement bearings for defects. Cracks and breaks should be repaired
should be equivalent to the original manufacturer’s and fits restored to manufacturer’s specifications.
specifications. 2.4.2 Mounting Surface Tolerances,
2.2.2 Sleeve Bearings Eccentricity and Face Runout
When sleeve bearings are remanufactured or • NEMA Type C face-mounting motors and Type
replaced by new bearings, the fit in the housing and D flange-mounting motors: See Table 2-8.
the diametral clearance should be set to original • NEMA Type P flange-mounting motors: See
equipment manufacturer’s specifications if available. Table 2-9.
See Section 9 of the EASA Technical Manual for • IEC flange-mounted machines: See Table 2-10
guidance on diametral clearances for oil-lubricated and Table 2-11.
horizontally-mounted sleeve bearings. Measure the 2.5 LAMINATIONS
new bearing dimensions. Examine stator and rotor laminations for evidence
Sleeve bearings should be uniform in diameter, of of hot spots or damaged or missing components.
proper fit in the housing, smooth internally, and suit-
ably grooved for adequate distribution of lubricant. 2.5.1 Rotors
Note: Not all sleeve bearing bores are cylindrical. The rotor laminations should be of proper fit on
the shaft, sleeve or spider on which the lamination
2.2.2.1 Sleeve Bearing End-Thrust
stack is assembled. The outer diameter of the rotor
Bearings of horizontal machines should be posi- laminations should be true and concentric with the
tioned on the shaft to eliminate end-thrust against bearing journals. Inspect stator and rotor for evi-
either bearing. dence of stator-rotor contact and visual evidence of
2.2.2.2 Oil Rings post-manufacture machining of the outer diameter
Oil rings should be true and rotate freely. Retain- of the rotor.
ers, when provided, should be inspected and replaced Cores should be examined for evidence of shorting
if necessary. or lamination hot spots. Testing may be needed (see
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Section 2, Page 2 EASA AR100-2010 Recommended Practice - Rev. October 2010
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 2, Page 3
vary the air gap of the interpoles to obtain satisfac- 2.13.3 Terminal Boards
tory commutation. Terminal boards should be replaced if damaged,
2.13 ACCESSORIES with components of the same ampacity and tempera-
ture rating of the original components.
2.13.1 Capacitors
2.13.4 Space Heaters
Capacitors should be tested for rated capacitance
Space heaters should be tested for rated current
and subjected to a high-potential test (see Paragraph
or power and subjected to a high-potential test (see
4.4). Capacitors should be replaced if damaged.
Paragraph 4.4). They should be replaced if damaged.
2.13.2 Starting Components and Switches
2.13.5 Temperature Sensors
Short circuit devices, centrifugal mechanisms,
Bearing and winding sensors or protectors should
switches, and starting relays should be verified
be identical with or equivalent to the original devices
for electrical and mechanical operation at correct
in electrical and thermal characteristics.
speed and voltage. These items should be replaced
if damaged.
Table 2-1. SHAFT EXTENSION DIAMETER TOLERANCES
NEMA MACHINES
DIMENSIONS IN INCHES DIMENSIONS IN MILLIMETERS
Shaft Diameter Tolerance Shaft Diameter Tolerance
0.1875 to 1.5000, incl. +0.000 -0.0005 4.76 to 38.1, incl. +0.000 -0.013
Over 1.5000 to 6.500, incl. +0.000 -0.001 Over 38.1 to 165.1, incl. +0.000 -0.025
Reference: NEMA Stds. MG 1, 4.9.1. Dimensions shown in millimeters are rounded off.
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Section 2, Page 4 EASA AR100-2010 Recommended Practice - Rev. October 2010
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 2, Page 5
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Section 2, Page 6 EASA AR100-2010 Recommended Practice - Rev. October 2010
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 2, Page 7
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Table 2-13. Radial Ball Bearing Fit Tolerances*
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Section 2, Page 9
Section 3, Page 1 EASA AR100-2010 Recommended Practice - Rev. October 2010
Section 3
Rewinding
3.1 INSPECTION 3.6 STATOR, ROTOR, AND
ARMATURE COILS
3.1.1 Core Laminations
Coil extensions should not be longer than the
Core testing is recommended before burnout or originals. The wire cross-sectional area should be
other equivalent process and after winding removal, at least equal to the original manufacturer’s speci-
and the results should be compared (see Paragraph fications.
4.2.8). Any increase in losses should be investigated,
3.6.1 Random-Wound Coils
and damaged laminations should be repaired or
Coils should be wound and inserted in the core
replaced.
slots with a minimum of crossed conductors. Care
3.1.2 Thermal Protectors or Sensors should be taken not to damage the insulation or
Thermostats, resistance temperature detectors conductors. Coils should be wedged with full-length
(RTDs), thermocouples and thermistors should be top sticks to hold them securely in the slots. Inter-
checked for electrical and physical defects. phase insulation should be used (where applicable).
3.2 REWIND SPECIFICATION 3.6.2 Form-Wound Coils
The winding should maintain the same electrical The fabricating of coil loops and the forming of
characteristics as the original. Winding data should these loops into the coil shape should be accom-
plished without damage to the conductor insulation.
be reviewed for accuracy.
Each layer of coil insulation should be uniformly
3.3 STRIPPING OF WINDINGS and tightly applied to minimize stress points and
Defective windings should be removed from the air voids.
core in a manner that will not damage the lamina- Coils should be placed in the core slots without
tions or other components. Part temperature should damaging the coil insulation. Coils should tightly fit
be controlled to avoid degradation of the inter- slots. Coils should be wedged to hold them securely
laminar insulation and distortion of any parts. The in the slots. Surge rings or similar supports should
be secured to the coils and the coils laced to one
oven should use a water suppression system. Parts
another as necessary to minimize coil distortion
should be oriented and supported in the oven so as
and movement.
to avoid distortion of the parts. Core slots should be
clean and free of sharp edges or particles. 3.7 FIELD COILS
Where high rigidity and a complete bonding of all
3.4 INSULATION SYSTEM the components is required, a high bond strength
The entire insulation system, materials, and meth- varnish or a thixotropic resin should be applied to
ods of application should be equal to or better than the ground insulation and to each layer of the coil
that used by the original machine manufacturer. during winding of the coil; otherwise, vacuum pres-
All components of the insulation system must be sure impregnation may be utilized when a complete
compatible with each other with respect to electrical, bond between insulation and conductors can be
mechanical, and thermal characteristics. The insu- ensured.
lation system should withstand the high-potential 3.7.1 Stationary Coils
tests described in Subsection 4.4 and the normal Varnish treatment of shunt, series and interpole
operation of the machine. coils is acceptable for coils originally manufactured
3.5 CONDUCTORS by this method.
The insulation of the outer coil layer should be
The current-carrying capacity, insulation, and
sufficient to withstand surges or inductive voltage
mechanical qualities of the conductors should be
spikes.
suitable for the environment in which the machine
is to operate. The temperature rating of the coil con- 3.7.2 Rotating Coils
ductor insulation should be equal to or higher than Coils and pole pieces should be securely wedged
that of the insulation system. If the conductor ma- and braced when installed.
terial is changed, it should be equal to or better than 3.8 SQUIRREL CAGE AND
the original material in all aspects of performance AMORTISSEUR WINDINGS
and application. Bars for squirrel cage and amortisseur wind-
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 3, Page 2
ings should fit tightly in the core slots. End rings should be laced, tied, or otherwise securely fastened
should be secured to the bars by welding or braz- to prevent movement.
ing, as appropriate for materials used. The winding The insulation should be applied so as to allow the
should maintain the same electrical, thermal and varnish/resin to penetrate.
mechanical characteristics as the original unless 3.12 WEDGES
redesigned by agreement with, or at the instruction
Wedges for stators, armatures and rotors should
of, the customer.
have adequate mechanical strength and thermal
For balancing, see Subsection 2.6.
rating to withstand normal operation of the machine.
3.9 THERMAL PROTECTORS OR Magnetic wedges should be replaced with equivalent
SENSORS magnetic wedges
Thermostats, resistance temperature detectors Wedges should fit tightly in the slots.
(RTDs), thermocouples and thermistors should be 3.13 BANDING OF ROTORS AND
identical with or equivalent to the original devices in ARMATURES
electrical and thermal characteristics and placed at Resin-filled glass banding tape may be applied
the same locations in the winding. Thermal protec- directly to the winding. It should be applied at the
tors or sensors should be removed or omitted only manufacturer’s recommended tension and method
with customer consent. of curing. The banding should be of sufficient thick-
3.10 SHAPING AND LACING OF ness and width to restrain the coils during normal
STATOR WINDINGS operation.
End windings should be shaped and laced as When wire banding is used, it should be applied
needed to provide the necessary clearance to the to the winding over banding insulation. The band-
rotor, stator, frame, bearing housings, air deflec- ing should match the original in location, material
tors and frame hardware. On machines with surge (magnetic or non-magnetic), wire size and number
rings (coil supports), the rings should be suitably of turns. The wire should be applied with sufficient
insulated, accurately fitted and laced to the coils to tension to hold the coils in place without distorting
ensure adequate support for the winding. The wind- them.
ing should maintain the same electrical, thermal and Caution: Replacing wire banding with resin-filled
mechanical characteristics as the original unless glass banding may change the magnetic circuit
redesigned by agreement with, or at the instruction configuration, affecting commutation and thermal
of, the customer. rating of the winding. Similar effects may result from
Restrictions to air flow should be avoided. replacing glass banding with wire banding.
3.11 COIL CONNECTIONS 3.14 IMPREGNATION OF WINDINGS
Windings of rewound machines should be pre-
3.11.1 Making Connections
heated, varnish/resin treated and cured using a
Connections which are made by crimping, solder- method of application and a material of sufficient
ing, brazing, or welding should use materials that thermal rating to withstand the normal operation
have adequate conductivity and are mechanically of the machine. The treatment should be compatible
strong enough to withstand the normal operating with the entire insulation system and suitable for
conditions. Materials such as solder paste, fluxes, the environment in which the machine is to operate.
inhibitors and compounds, where employed, should
be neutralized after using. These materials should be
suitable for the intended use and of a type that will
not adversely affect the conductors. Soldered joints
should not be used in place of brazed or welded joints.
Connections and splices should be so constructed
as to have resistance no greater than that of the
conductors.
3.11.2 Insulating Connections
Connections should be adequately insulated to
withstand the temperature and voltage ratings
of the machine and be mechanically adequate to
withstand normal operation. Connections and leads
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Section 4, Page 1 EASA AR100-2010 Recommended Practice - Rev. October 2010
Section 4
Testing
4.1 SAFETY CONSIDERATIONS RECOMMENDED MINIMUM INSULATION
See Appendix for safety considerations. RESISTANCE VALUES AT 40° C
(All Values in MΩ)
4.2 INSULATION CONDITION
INSPECTION AND TESTS Minimum Insulation
Test Specimen
Tests should be performed to indicate the suit- Resistance
ability of the insulation for continued operation. For most windings made before
Insulation resistance tests should be performed with IR1min = kV + 1 about 1970, all field windings, and
acceptable results before the high-potential tests. others not described below.
Other tests, indicated below, may also be applied. All For most DC armature and AC
test results should be retained. Trends in results are IR1min = 100 windings built after about 1970
often better condition indicators than the absolute (form-wound coils).
values (Reference: IEEE Stds. 95). For most machines with random-
4.2.1 Insulation Resistance Test IR1min = 5 wound stator coils and form-
Test voltage should be applied for one minute. wound coils rated below 1 kV.
(Reference: IEEE Stds. 43, Sec. 5.4 and 12.2.) Notes:
1 IR1min is the recommended insulation resistance, in megohms,
GUIDELINES FOR DC at 40° C of the entire machine winding.
VOLTAGES TO BE APPLIED DURING 2 kV is the rated machine terminal-to-terminal voltage, in rms
kV.
INSULATION RESISTANCE TEST
Reference: IEEE Stds. 43, Table 3.
Winding Rated Insulation Resistance Test
Voltage (V)a Direct Voltage (V)
results of tests on similar machines. No standard
<1000 500
interpretation of results has been established (Ref-
1000 - 2500 500 - 1000 erence: IEEE Stds. 432, Sec. 8.1).
2501 - 5000 1000 - 2500 4.2.4 Step Voltage Test
5001 - 12,000 2500 - 5000 Step voltage tests are useful if performed at regu-
>12,000 5000 - 10,000 lar maintenance intervals. Changes in results may
a Rated
indicate insulation degradation (Reference: IEEE
line-to-line voltage for three-phase AC machines, line-to-
ground for single-phase machines, and rated direct voltage for DC Stds. 95).
machines or field windings. 4.2.5 Turn-To-Turn Test
Reference: IEEE Stds. 43, Table 1. Accepted methods of testing turn-to-turn insu-
lation vary widely. No single standard procedure
4.2.2 Polarization Index (P.I.) Test applies, although several standards touch on the
The polarization index (P.I.) test should be per- subject (IEEE Stds. 432, 522, and 792; and NEMA
formed at the same voltage as the test in Paragraph Stds. MG 1, 12.5).
4.2.1 for ten minutes. The recommended minimum 4.2.6 Surge Comparison Testing
value of polarization index for windings rated Class
The surge comparison test is most often applied
B and higher is 2.0 (References: IEEE Stds. 43, Sec.
to winding circuits using a test voltage of twice the
9.2; and IEEE Stds. 432, App. A2).
circuit rating plus 1000 volts.
If the one minute insulation resistance is above
5000 megohms, the calculated polarization index 4.2.7 Interlaminar Insulation Test
(P.I.) may not be meaningful. In such cases, the P.I. Defects in laminated cores can be detected by
may be disregarded as a measure of winding condi- loop or core tests (Reference: IEEE Stds. 432, Sec.
tion (Reference: IEEE 43, Sec. 5.4 and 12.2). 9.1, App. A4).
4.2.3 Insulation Power Factor Tests 4.2.8 Bearing Insulation Test
Insulation power factor, dissipation factor, and Bearing insulation should be tested with a 500V
tip-up tests may be performed on large machines. megohmmeter. Insulation resistance should be 1
Interpretation of results is by comparison with megohm or greater.
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 4, Page 2
4.3 RECOMMENDED WINDING TESTS Machines to be tested must be clean and dry.
Windings should be tested to ensure that there are Inspection and insulation resistance tests with
no grounds, short circuits, open circuits, incorrect acceptable results should be performed before the
connections or high resistance connections. high-potential tests. Insulation resistance tests
4.3.1 Stator and Wound-Rotor Windings should be repeated at the completion of the high-
potential tests.
One or more of the following tests should be per-
When a high-potential test is conducted on an as-
formed:
sembled brushless exciter and synchronous machine
(1) Insulation resistance test.
field winding, the brushless circuit components (di-
(2) Winding resistance test.
odes, thyristors, etc.) should be short-circuited (not
(3) Growler test.
grounded) during the test.
(4) Phase-balance test.
High-potential tests should be successively applied
(5) Surge comparison test.
between each winding or electric circuit under test
(6) Polarity test.
and the frame (or core) of the machine. All other
(7) Ball rotation test (low voltage energization).
windings or electric circuits not under test should
4.3.2 Squirrel Cage Windings be connected to the frame (or core).
One or both of these tests should be performed: Capacitors of capacitor-type motors must be left
(1) Growler test. connected to the winding in the normal manner for
(2) Single-phase test. machine operation (running or starting).
4.3.3 Armature Windings Electrical machines may be tested using AC or DC
One or more of the following tests should be high-potential test equipment. A DC instead of an
performed: AC voltage may be used for high-potential tests. In
(1) Insulation resistance test. such cases, the DC test voltage should be 1.7 times
(2) Growler test. the specified AC voltage. A failure under test can be
(3) Surge comparison test. less damaging to the winding if a DC voltage is used.
(4) Bar-to-bar resistance or voltage drop test. AC high-potential testing should be performed by
applying specified voltage at 50-60 Hz continuously
4.3.4 Shunt, Series, Interpole,
for one minute.
Compensating and Synchronous
DC high-potential testing should be performed
Rotor Windings
by applying specified voltage for a duration of one
One or more of the following tests should be minute after test voltage is reached. The DC poten-
performed: tial should be increased gradually to the desired
(1) Insulation resistance test. test voltage in order to limit the charging current.
(2) Winding resistance test. Caution: After completion of a DC high-potential
(3) Surge comparison test. test, the winding must be grounded to the frame (or
(4) Voltage drop test (DC or AC voltage), coils in core) until the charge has decayed to zero. (Refer-
series. ences: IEEE Stds. 4 and 95; and NEMA Stds. MG 1,
The variation in DC voltage drops should 3.1.1.)
not be greater than 5% between coils of
same field circuit. 4.4.1 Windings
10% variation in AC test results is accept- 4.4.1.1 New Windings
able if the DC test is within limit. High-potential tests should be applied as specified
4.3.5 Interconnection of Windings in Table 4-1 for AC voltage and Table 4-2 for DC
Shunt, series, interpole, compensating, and syn- voltage. To avoid excessive stressing of the insula-
chronous rotor windings should be tested to ensure tion, repeated application of the high-potential test
that the polarities and connections are correct. voltage is not recommended. Immediately after
Terminal and lead markings should comply with rewind, when equipment is installed or assembled
Subsection 1.5. and a high-potential test of the entire assembly is
4.4 HIGH-POTENTIAL TESTS required, it is recommended that the test voltage
not exceed 80% of the original test voltage. The tests
High-potential tests should be performed on wind-
should be applied once only at the specified voltage.
ings and certain accessories of electrical machines
(Reference: NEMA Stds. MG 1, 12.3.)
at a specified voltage. To avoid excessive stressing
of the insulation, repeated application of the high- 4.4.1.2 Reconditioned Windings
potential test voltage is not recommended. High-potential tests for reconditioned windings
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Section 4, Page 3 EASA AR100-2010 Recommended Practice - Rev. October 2010
should be performed at 65% of the new winding should be run with rated voltage applied to the
test value. armature, and rated current applied to the shunt
4.4.1.3 Windings Not Reconditioned field. The speed should be measured and compared
Machines with windings not reconditioned should with nameplate speed.
have an insulation resistance test instead of a high- Series-wound motors should be separately excited
potential test. when tested due to danger of runaway.
DC generators should be driven at rated speed
4.4.2 Accessories with rated current applied to the shunt field. The
4.4.2.1 New Accessories output voltage should be measured and compared
Accessories such as surge capacitors, lightning ar- with rated voltage.
resters, current transformers, etc., which have leads 4.5.2 Current
connected to the machine terminals should be dis- No-load current should be recorded.
connected during the test, with the leads connected
4.5.3 Cooling System
together and to the frame or core. These accessories
should have been subjected to the high-potential test The cooling system should be verified as being
applicable to the class of machine at their point of operational.
manufacture. Capacitors of capacitor-type motors 4.5.4 Sound Level
must be left connected to the winding in the normal Tests may be made for sound level as an indication
manner for machine operation (running or starting). of fault or as an irritation to those in the machine
Component devices and their circuits, such as ambient (Reference: NEMA Stds. MG 1, Part 9).
space heaters and temperature sensing devices in
contact with the winding (thermostats, thermocou- 4.5.5 Bearing Temperature
ples, thermistors, resistance temperature detectors, Ambient and bearing housing temperatures may
etc.), connected other than in the line circuit, should be measured periodically until temperatures are
be connected to the frame or core during machine stabilized.
winding high-potential tests. Each of these compo- 4.5.6 Vibration Tests
nent device circuits, with leads connected together, The vibration tests should be in accordance with
should then be tested by applying a voltage between NEMA Stds. MG 1, 7 for standard machines, as ar-
the circuit and the frame or core. The high-potential ranged with the customer, or as necessary to check
tests should be applied as specified in Table 4-3 for the operating characteristics of the machine. When
AC voltage and Table 4-4 for DC voltage. During each there are special requirements, i.e., lower than
device circuit test, all other machine windings and standard levels of vibration for a machine, NEMA
components should be connected together and to the Stds. MG 1, 7 for special machines is recommended.
frame or core. (Reference: NEMA Stds. MG 1, 3.1.8.) The unfiltered vibration limits for resiliently
4.4.2.2 Accessories of Machines with mounted standard machines (having no special
Reconditioned Windings vibration requirements), based on rotational speed,
The high-potential test for accessory circuits of are shown in Table 4-5. Vibration levels for speeds
reconditioned machines should be performed at 65% above 1200 rpm are based on the peak velocity of
of the new device test value. 0.15 inch per second (3.8 mm/s). Vibration levels
for speeds below about 1200 rpm are based on the
4.4.2.3 Accessories of Machines with
peak velocity equivalent of 0.0025 inch (0.0635 mm)
Windings Not Reconditioned
peak-to-peak displacement. For machines with rigid
Accessory circuits of machines which have not had
mounting, multiply the limiting values by 0.8.
their windings reconditioned should have an insula-
Note: International standards specify vibration
tion resistance test instead of a high-potential test.
velocity as rms in mm/s. To obtain an approximate
4.5 NO-LOAD TESTS metric rms equivalent, multiply the peak vibration
in in/s by 18 (Reference: NEMA Stds. MG 1, 7.8).
4.5.1 Speed
For AC motors, no-load running tests should be 4.6 TESTS WITH LOAD
made at rated voltage and rated frequency. The Tests with load may be made as arranged with
speed should be measured and compared with the customer or as necessary to check the operating
nameplate speed. characteristics of the machine (References: IEEE
Shunt-wound and compound-wound DC motors Stds. 112 and 115 and NEMA Stds. MG-1).
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EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 4, Page 4
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Section 4, Page 5 EASA AR100-2010 Recommended Practice - Rev. October 2010
18
EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 4, Page 6
UNIVERSAL MOTORS RATED 250 VOLTS OR LESS FIELD WINDING ARMATURE WINDING
Rated 0.5 hp and less, except motors marked
1000 volts
for portable tools
Rated greater than 0.5 hp, and all motors marked for 1000 volts + 2 times the
portable tools rated voltage of the motor
* The brushless circuit components (diodes, thyristors, etc.) should be short-circuited (not grounded) during the test.
References: NEMA Stds. MG 1, 12.3, 15.48, 20.17, 21.22.4, 21.22.5, 23.20 and 24.49.
19
Section 4, Page 7 EASA AR100-2010 Recommended Practice - Rev. October 2010
* Starting Method 1: For a motor to be started with its field short-circuited or closed through an exciting armature.
Starting Method 2: For a motor to be started with a resistor in series with the field winding. The IR drop is taken as the product of
the resistance and the current that would circulate in the field winding if short-circuited on itself at the specified starting voltage
(Reference: NEMA Stds. MG 1, 21.22.3).
Caution: After completion of a DC high-potential test, the winding must be grounded to the frame (or core) until the charge has decayed to
zero. (References: IEEE Stds. 4 and 95; and NEMA Stds. MG 1, 3.1.)
20
EASA AR100-2010 Recommended Practice - Rev. October 2010 Section 4, Page 8
UNIVERSAL MOTORS RATED 250 VOLTS OR LESS FIELD WINDING ARMATURE WINDING
Rated 0.5 hp and less, except motors marked
1700 volts
for portable tools
Rated greater than 0.5 hp, and all motors marked for 1700 volts + 3.4 times the
portable tools rated voltage of the motor
* The brushless circuit components (diodes, thyristors, etc.) should be short-circuited (not grounded) during the test.
References: NEMA Stds. MG 1, 12.3, 15.48, 20.17, 21.22.4, 21.22.5, 23.20 and 24.49.
Caution: After completion of a DC high-potential test, the winding must be grounded to the frame (or core) until the charge has decayed to
zero. (References: IEEE Stds. 4 and 95; and NEMA Stds. MG 1, 3.1.)
21
Section 4, Page 9 EASA AR100-2010 Recommended Practice - Rev. October 2010
22
EASA AR100-2010 Recommended Practice - Rev. October 2010 Appendix, Page 1
Appendix
Electrical Testing Safety Considerations
(This Appendix is not a part of EASA AR100-2010, Recommended Practice for the Repair of Rotating Electrical Apparatus.)
23
Appendix, Page 2 EASA AR100-2010 Recommended Practice - Rev. October 2010
24
EASA AR100-2010 Recommended Practice - Rev. October 2010 Bibliography, Page 1
Bibliography
All references are to the revision dates listed below.
ANSI/ABMA Standard 7-1995: Shaft and Housing IEEE Standard 112-2004: IEEE Standard Test
Fits for Metric Radial Ball and Roller Bearings Procedure for Polyphase Induction Motors and
(Except Tapered Roller Bearings) Conforming to Generators. Institute of Electrical and Electronics
Basic Boundary Plans. American Bearing Manu- Engineers, Inc. New York, NY, 2004.
facturers Association, Inc. and American National
IEEE Standard 115-1995: IEEE Guide: Test Pro-
Standards Institute. New York, NY, 1995.
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Rotating Machines With Speed Ranges From York, NY, 1996.
10 to 200 RPS. Measurement And Evaluation of
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Standards Institute. New York, NY, 1985; re-
to less than 10 000 hp). Institute of Electrical and
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International Organization for Standardization;
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1995 but retained by ANSI.) Turn-To-Turn Insulation on Form-Wound Stator
Coils for Alternating-Current Rotating Electric
ANSI/NCSL Z540-1-1994: Calibration–Calibration Machines. Institute of Electrical and Electronics
Laboratories and Measuring and Test Equip- Engineers, Inc. New York, NY, 2004.
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Standards Institute. New York, NY, 1994. IEEE Standard 792-1995: IEEE Recommended
Practice for the Evaluation of the Impulse Voltage
IEC Standard Publication 60034-8: Rotating Elec- Capability of Insulation Systems for AC Electric
trical Machines, Part 8: Terminal Markings and Machinery Employing Form-Wound Stator Coils.
Direction of Rotation of Rotating Machines. Inter- Institute of Electrical and Electronics Engineers,
national Electrotechnical Commission. Geneva, Inc. New York, NY, 1995.
Switzerland, 2002; second edition, 2007.
IEEE Standard 1068-1996: IEEE Recommended
IEC Standard Publication 60072-1: Part 1–Frame Practice for the Repair and Rewinding of Motors
Numbers 56 to 400 and Flange Numbers 55 to for the Petroleum and Chemical Industry. Institute
1080. International Electrotechnical Commission. of Electrical and Electronics Engineers, Inc. New
Geneva, Switzerland; seventh edition, 2000. York, NY, 1997.
IEC Standard Publication 60136: Dimensions of ISO 10012-1: Quality Assurance Requirements for
Brushes and Brush-holders for Electric Machin- Measuring Equipment. International Organiza-
ery. International Electrotechnical Commission. tion for Standardization. Geneva, Switzerland,
Geneva, Switzerland; second edition, 1986. 1992.
IEEE Standard 4-1995: Standard Techniques for ISO 1940-1: Mechanical Vibration–Balance Qual-
High-Voltage Testing. Institute of Electrical and ity Requirements of Rigid Rotors. International
Electronics Engineers, Inc. New York, NY, 1995. Organization for Standardization. Geneva, Swit-
zerland, 1986.
IEEE Standard 43-2000: IEEE Recommended Prac-
tice for Testing Insulation Resistance of Rotating ISO 1940-2: Determination of Permissible Residual
Machinery. Institute of Electrical and Electronics Unbalance. International Organization for Stan-
Engineers, Inc. New York, NY, 2000. dardization. Geneva, Switzerland, 1997.
IEEE Standard 95-2002: IEEE Recommended Prac- ISO 10816-1: Mechanical Vibration–Evaluation of
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Machinery with High Direct Voltage. Institute of Rotating Parts–Part 1: General Requirements.
Electrical and Electronics Engineers, Inc. New International Organization for Standardization.
York, NY, 1977; 2002. Geneva, Switzerland, 1995.
25
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NEMA Standards MG 1-2006: Motors and Gen- 29CFR1910.331 - .335 OSHA: Electrical Safety-
erators. National Electrical Manufacturers Related Work Practices. Occupational Safety
Association. Rosslyn, VA; 2006. And Health Administration. Washington, DC;
revised 2002.
NFPA Standard 70E-2009: Standard for Electrical
Safety in the Workplace. National Fire Protection
Association, Quincy, MA; 2009.
26
EASA AR100-2010 Recommended Practice - Rev. October 2010 Standards Organizations, Page 1
* IEC and ISO standards are available through ANSI, which is the American representative to all international standards groups.
27
Standards Organizations, Page 2 EASA AR100-2010 Recommended Practice - Rev. October 2010
NIST–National Institute of
Standards and Technology
100 Bureau Dr.
Stop 1070
Gaithersburg, MD 20899-1070
301-975-6478
Federal Relay Service: 800-877-8339 (TTY)
Web Site: www.nist.gov
E-mail: inquiries@nist.gov
28
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